TOYOTA BODY AND PAINT

1 TPS . . Kaizen KaizenJust In TimeKanbanHeijunkaJidokaStandardized WorkPull SystemFlexible Manpower LineTakt Time . . ( ) . .

$ 5Addresses three goals of a competitive companyImportance of a visual workplace

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. . :Genchi . .Genchi Gembutsu( ) :Gembutsu . . .

1. . - Genchi Gembutsu

2. .TSM Basic Use the 5 Ws What Where When - Who Why How 9Combination of PDCA cycle and Toyota problem solving3 . . .5 : : .: : .: : .: : .: : rubber seal .TSM Basic : . : .4. Action plan .6. .5. action plan .7. .TSM Basic PolicyTime Gemba( ) :

.13Continually Improving (Kaizen)

Constantly reducing waste can be seen as removing snow only to expose ice - as you go lower, the real obstacles become more visible (and harder)Weve already shared examples of some types of waste that immediately come to mind. Heavy snow (or waste) inhibits our ability to move easily (efficiency). Our goal is to get to solid ground. As we knock off the easy waste items and begin to lower the snow level, we start to hit some hard ice.Often the easy waste we can eliminate is only a symptom. Much of the snow is easily removed. As we discover the hard ice, however, the removal becomes more difficult. Now were arriving at the root causes.When we eliminate waste at the root, it cant grow back again.The following principles can be used to look at any physical environment from your workspace to your garage and begun to quickly identify opportunities for improved efficiency.

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.Muda .

() Muda Muda -

Anything that does not add value to the process

.Muda 7 1- 2- 3-

4- 16Main points:7 Main Categories of Muda:1) Overproduction:Producing more than is immediately required2) Waiting:Watching a machine run through its cycle3) Conveyance:Moving WIP from one process to another4) Processing:Extra processing, beyond cust. requirements5) Inventory:High amount of standard in-process in stock 6) Motion:Excessive bending, reaching, lifting or walking7) Correction (rework):Time spent sorting and fixing quality defects5- .6- 7- ()

Mudas 7

. . . . .20After condition - Increased value added activity, decreased motion, walk, and wait time 5 . .Taiichi Ohno